Vacuumed-Formed or Injected Sub Shell for Static Reinforcement of Bathub Shell

ABSTRACT

The present invention relates to methods for joining a sub-shell for static reinforcement of a bathtub to a bathtub and a bathtub produced using said methods. This invention also relates to the section of sanitary and bath equipment made of plastic materials.

FIELD OF THE INVENTION

The present invention relates to methods for joining a sub-shell forstatic reinforcement of a bathtub to a bathtub and a bathtub producedusing said methods. This invention also relates to the section ofsanitary and bath equipment made of plastic materials.

BACKGROUND OF THE INVENTION

Technical problem to be solved by this invention is: how to provide thestatic reinforcement of bathtub shells not using materials suchpolyester resins, glass fibers, various fillers and toxic volatilesolvents, and to get final products of the same or better quality.

Presently, the most used process for production of bathtubs, suchdescribed in for example in GB Patent application No. 2 266 261 (KlausJurgen, Fileis Roger, Folkard, 1993), made of plastic polymers includesproviding an additional reinforcement of the bathtub shells.Reinforcement of a bathtub shell, regardless of the way it was produced,consists of sub-shell containing a mixture of polyester resin or glassfiber or some tillers, some specific chemical components as catalystsand solvents for chemical reactions. Said process could be performedonly by using expensive equipment.

However, process from this application has a number of shortcomings,such as:

-   -   a rather extended production process;    -   ecological unacceptable production process causing exhausting of        toxic and flammable substances;    -   using glass fibers in production process and in final        installation of product bears a high risk of mechanical injuring        of the workers;    -   high participation of various kinds of materials;    -   expensive equipment for application of polyester resin and glass        fiber;    -   higher loses of material such as polyester resin in producing        bathtub shells;    -   recycling of waste plastic materials is impossible because of        using several different materials.

Above mentioned shortcomings were a stimulus to author to drop existingprocess and made a completely new process for production of bathtubsmade of plastic polymers.

SUMMARY OF THE INVENTION

This invention relates to completely new processes for staticreinforcement of bathtub shells. These processes are related toproduction of one or more sub-shells using the same material used toproduce bathtub shell.

One or more sub-shells are produced of the same material used to producebathtub shell, applying some of known processes (using vacuum or byinjecting plastic materials).

Basic shape of sub-shell follows the shape of the bathtub shell, thesub-shell's bottom being profiled with regularly disposed polygonalbulges, reminding of honeycombs.

This invention has, according to this patent application, a number ofadvantages, some of the more essential being:

-   -   increased stability and much faster and cheaper production        process    -   qualitative, simple and fast produced static reinforcement of        the bathtub shell.    -   easy and fast connecting the sub-shell to bathtub shell    -   completely eliminated the use of polyester resin, glass fibers,        fillers and equipment for application of said materials    -   ecological acceptable and conformed production procedures in all        phases, including the installation of the final product    -   no extra costs in the production, sub-shell being made of the        same material as the bathtub shell    -   a (grand) serial production is possible.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows, schematic, connection between the walls of the bathtub andthe sub-shell in the case of the first variant of their connecting,

FIG. 2 shows the second variant of the connection,

FIG. 3 shows, schematic, the placing of bathtub in its sub-shell,

FIG. 4 is a plan view of a bathtub produced by a process according tothe present invention,

FIG. 5 shows the side view of the bathtub shown on FIG. 4,

FIG. 6 shows the longitudinal section of the bathtub shown on FIG. 4,

FIG. 7 shows a cross section of the bathtub shown on FIG. 4,

FIG. 8 shows the lower view of the bathtub shown on FIG. 4,

FIG. 9 shows a detail of the supporting part of the sub-shell, said partproviding support on the floor for the bathtub, and

FIG. 10 shows a section of the detail shown on FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

1. Description of processes. Equipment necessary for the production ofsub-shells for static reinforcement of bathtub shells is the same as theexisting one used for production of bathtub shells, either by usingvacuum or by applying some of known processes such as injecting ofplastic materials.

Mold used for providing sub-shells of desired form is of nearly the samesize as the mold used for obtaining the basic product—the bathtubshells. Only difference between said molds is in that the mold forproducing the sub-shell is providing a basic form for sub-shell—reliefprofiled surfaces with a number of polygonal bulges.

Once the bathtub shell and sub-shell are fished, bathtub (a) ispositioned in the sub-shell (b), as schematic shown in FIG. 3, followedby joining bathtub shell to the sub-shell.

1. Process of Joining the Bathtub Shell to the Sub-Shell for StaticReinforcement of Bathtub Shell by Using Some Kind of Glue.

Pasting the bathtub shell to sub-shell is made with a glue obtained b\mixing sawdust, made of wastes obtained during final processing ofbathtub shells and sub-shells, with some saturated benzole basedsolution.

Sub-shell, produced either by casting or in a mold for vacuum casting,is covered on the inner side with a rather thin layer of glue, eitherwith a brush or by using some spraying tools.

Following stage starts immediately after covering the inner side of thesub-shell with a layer of glue. The bathtub shell is placed in thesub-shell (FIG. 3). Its outer surface is contacting the inner surface ofthe sub-shell, i.e. its flat surfaces covered with glue. The process ofjoining evolves so that the outer part of the bathtub shell contactingthe flat surfaces covered with glue starts, when contacting the glue, todissolve mildly, thus provoking the process of joining the bathtub shellto the sub shell Final result of said process is a bathtub wallconsisting, as shown in FIG. 1, of three layers' layer (1) containingmaterial of the bathtub shell, layer (2) containing material of thesub-shell and a middle layer (3) containing the glue material.

The basic process of joining takes up to one hour, depending on thethickness of the glue layer, the total time for finishing said processis twelve hours.

Next step is the final mechanical treatment of edges and apertures.

2. Process of Joining the Bathtub Shell to the Sub-Shell for StaticReinforcement of Bathtub Shell by Ultrasonic Welding.

For the joining by ultra sonic welding it is necessary to provide aminimum clearance between the bathtub shell and sub-shell.

After putting the bathtub shell into the sub-shell (FIG. 3) starts theprocess of ultrasonic-welding by applying appropriate devices. Finalresult of said process is a bathtub wall consisting, as shown in FIG. 2,of two layers: layer (1) containing material of the bathtub shell andlayer (2) containing material of the sub-shell.

2. The bathtub constructed using the processes according to thisinvention. Based on described processes, there is produced a bathtubhaving a bathtub shell joined to a sub-shell for the staticreinforcement of the bathtub shell. There is shown a bathtub made by theprocess containing the gluing together the walls of bathtub shell andsub-shell.

Bathtub (4) has, in a plan view, standard rectangular shape (FIG. 4).The side view (FIG. 5) has a customary shape, but on the lower edgethere is shown a number of bulges (6). On FIG. 6 there is shown thesection B-B from the FIG. 4. It should be noted that bulges (6) arehollow.

On FIG. 7 there is shown the section A-A from the FIG. 4, including adetail showing the gluing of the walls of bathtub shell and sub-shell.

On FIG. 8 is shown the lower view of the bathtub shown on FIG. 4. Therecould be seen the bottom of the sub-shell (2) covered with bulges (6).On FIG. 9 is shown a detail M of the supporting part of the sub-shellfrom which it could be seen that the bulges (6) consist of a net ofhexagonal hollow bulges the bottom (7) thereof being the part ofsub-shell.

The bathtub bottom is supported by bulges (6) which take over the weightof the bathtub and transfer it, through their hexagonal walls, in theground.

1. Vacuumed-injected sub shell for static reinforcement of bathtub shellsignified with that, which concerns production of sub shell from plasticmaterials which are the same like materials that bathtub shell is made.2. Sub shell by request 1, signified with that, which in connectingprocess with bath tub shell using plastic material received as waste insub shell outline treatment and drilling of holes for connecting oncanalization network. The waste is collected and in specific tank mixedwith solvent on benzyl base until final solvent.
 3. Vacuumed-injectedsub shell by request 1, signified with that, which is on inner sideapplied with solvent, after what is in sub shell placed bathtub shell.On that moment start the process of binding.
 4. Vacuum-injected subshell for static reinforcement of bathtub shell, by request 2, signifiedwith that, that construction and basic shape of the sub shell (2),follows the shape of the bathtub shell (1).
 5. Vacuumed-injected subshell by request 2, signified with that, which the whole her surface isprofiled, with convexes on inner side with straight upper sides (5). 6.Vacuumed-injected sub shell, by request 2, signified with that, whichoutside part of the bathtub shell with its all surface recline andconnect with straight upper surfaces profiled convexes (5).